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Date:  9-28-2022
Number of Hours:  1.20
Manual Reference:  23-03
Brief Description:  Cowling upper flanges and oil check door

Trimmed oild check door lip and trial fitted hinge. Discover the flange along the hinge line is a woftam, as it ALL needs to be cut away to fit the hinge. With the hinge trial fitted over the flange the door is not level with the cowling surface either. Sanded all the upper flange away, and still didn't take any pictures...

Trial fitted door with the opening spring I got from ASS, but note the door strongly wants to pop open without it. Install with BSC-44 pop rivets and flox, and cover heads with a smear of flox and 1 x 4oz.

After completion I am disgusted to see the door no longer pops up on its own. Dang! Cannot be bothered to remove and start again, but I'll carefully put away the springy thingie.

Applied 1 x BID over the wing cowl flanges upper surface, and peel ply edge.

Am perplexed by the hand amendment to the layup schedule for the brace from the inside of the upper cowl flange to the rear face of the firewall and the spar. It was originally 1 x BID, and has been hand amended to 5 x BID. I believe this will have a tragic effect on fitting the cowling it, and I'm just not going to do it. I whack in a flox fillet to help with the transition and layup 2 x UND overall using tapes cut on a 45 degree bias, the plies crossing at 90 degrees. I padded this with 2 x BID in the sharp corners. This was an excruciating layup with the engine fitted. I'll do the lower flange reinforcementwith the engine off. [Timewarp: The flange over the strakes seems as strong as, but the flange on the turtleback is a bit bendy. I later added another 5 x UND at 90/45 in the wobbly bits].
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Reinforcing the wing cowling flange

Reinforcing the wing cowling flange

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Taping the strake/turtleback cowling flange to the spar/firewall

Taping the strake/turtleback cowling flange to the spar/firewall

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Contortioning...

Contortioning...

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